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EP0175662B1 - Method of manufacturing loop-formed metal foil elements - Google Patents

Method of manufacturing loop-formed metal foil elements Download PDF

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Publication number
EP0175662B1
EP0175662B1 EP85850249A EP85850249A EP0175662B1 EP 0175662 B1 EP0175662 B1 EP 0175662B1 EP 85850249 A EP85850249 A EP 85850249A EP 85850249 A EP85850249 A EP 85850249A EP 0175662 B1 EP0175662 B1 EP 0175662B1
Authority
EP
European Patent Office
Prior art keywords
loop
elements
metal foil
loop elements
punching
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP85850249A
Other languages
German (de)
French (fr)
Other versions
EP0175662A1 (en
Inventor
Tommy Fredriksson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kanthal AB
Original Assignee
Kanthal AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kanthal AB filed Critical Kanthal AB
Publication of EP0175662A1 publication Critical patent/EP0175662A1/en
Application granted granted Critical
Publication of EP0175662B1 publication Critical patent/EP0175662B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
    • H05B2203/003—Heaters using a particular layout for the resistive material or resistive elements using serpentine layout
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
    • H05B2203/005—Heaters using a particular layout for the resistive material or resistive elements using multiple resistive elements or resistive zones isolated from each other
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/014—Heaters using resistive wires or cables not provided for in H05B3/54
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/029—Heaters specially adapted for seat warmers
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/037—Heaters with zones of different power density
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49083—Heater type
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49087—Resistor making with envelope or housing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49789—Obtaining plural product pieces from unitary workpiece
    • Y10T29/49794—Dividing on common outline

Definitions

  • the present invention relates to a method of manufacturing loop-formed metal foil elements intended to serve as electrical resistance heating elements. Similar loop-formed foil elements are known from DE-A-3334744.
  • Such metal foil elements are known, e.g., from SE-A-7713250-4, and are being used more and more for various heating purposes, e.g. for heating car seats or other flexible surface elements, or for heating rigid surfaces, possibly having a complicated geometrical, in particular curved shape.
  • the object of the invention is to achieve a manufacturing method in which the waste of material is considerably reduced and, moreover, permitting an especially simple method, namely punching.
  • this object is achieved by simultaneously forming, particularly by punching, at least two complementarily extending loop elements, one inside the other.
  • difference in length, and thus in resistance, of two adjacent meander-shaped loop elements of the same width only amounts to a few percent, and such loop elements can therefore be used for the same purpose, e.g. in car seats.
  • two or three loop elements located one inside the other, can be formed at the same time, but in principle, even four or more-loop elements may be produced.
  • the material can be used up to about 70-80%, which means a considerable economic saving compared to conventional manufacturing methods.
  • the waste obtained when forming by punching is more favourable for re-use than by etching.
  • the loop elements located inside each other will be approximately equal in length. If so desired, the actual differences in length, which are small, may be compensated by making the shorter loop elements somewhat narrower so that the resistance becomes equal.
  • the punching is performed by means of stamp and die, but principally, even a cutting punch can be used.
  • a possible alternative to the punching operation is conventional production by etching the loop elements located inside each other.
  • a metal foil is applied to a supporting layer, preferably of thermoplastic material, such as polyester, and after etching the complementary loop elements a cover layer may be applied. Thereafter, the loop elements are punched out together with the metal foil loops enclosed between the enclosing layers.
  • Fig. 1 consists of two foil loop elements 1, 2 located one (element 1) closely inside the other(element 2) and having complementary meander loop portions, also shown in Figs. 2 and 3, illustrating the configuration of each loop element 1, 2.
  • the different loop portions extend in different main directions, i.e. substantially perpendicular to each other.
  • the metal foil is made of a rustproof plate material having a thickness of about 35 pm.
  • the metal foil is enclosed at both sides by polyester plastic which is punched simultaneously in one operation by means of a punch tool formed in correspondence to the configuration shown in Fig. 1.
  • the metal foil may have a thickness of 20-100pm. If three loop elements are punched out at the same time, the thickness should be larger than the thickness of only two coil members, e.g. about 50 um.
  • the punched out loop elements are short circuited by a metal connection C1 (Fig. 2) and C2 (Fig.3), respectively.
  • the purpose of this connection is to make the element stable enough during the assembly of the connection cables and an outer casing, e.g. in the form of a plastic net. Thereafter, the connection is cut away.
  • one of the plastic foils e.g. the lower one, may have larger dimensions than the metal foil and the other plastic foil, so that a protruding plastic foil portion (not to be punched) constitutes the desired connection, which provides the member with the necessary stability during assembly.
  • the form of the loop may vary at wish in view of the intended use.
  • the meander loops may extend in mutually oblique main directions or in only one main direction.
  • the loop elements do not necessarily have to be meander-shaped, but may have any, preferably closed configuration.
  • the essential feature is that the loop elements are situated complementarily one inside the other and together cover the major part of the surface area in question so as to reduce the waste of material.

Landscapes

  • Surface Heating Bodies (AREA)
  • Laminated Bodies (AREA)
  • Apparatuses And Processes For Manufacturing Resistors (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Punching Or Piercing (AREA)

Description

  • The present invention relates to a method of manufacturing loop-formed metal foil elements intended to serve as electrical resistance heating elements. Similar loop-formed foil elements are known from DE-A-3334744.
  • Such metal foil elements are known, e.g., from SE-A-7713250-4, and are being used more and more for various heating purposes, e.g. for heating car seats or other flexible surface elements, or for heating rigid surfaces, possibly having a complicated geometrical, in particular curved shape. For such purposes, it is usually essential that the loop-formed metal foil element covers a relatively large surface area, although for one reason or another the mutually adjacent parts of the loop element should preferably be well separated from each other, e.g. to enable stretching during assembly or use of the element.
  • The manufacture of such loop elements with relatively sparsely distributed loop portions has hitherto involved a great waste of material, since the material between the loop portions was discarded. Moreover, conventional methods of printing and etching of loop patterns are extremely complicated and cumbersome.
  • The object of the invention is to achieve a manufacturing method in which the waste of material is considerably reduced and, moreover, permitting an especially simple method, namely punching.
  • Starting from a unitary metal foil, this object is achieved by simultaneously forming, particularly by punching, at least two complementarily extending loop elements, one inside the other. In this connection, it has rather surprisingly turned out that the difference in length, and thus in resistance, of two adjacent meander-shaped loop elements of the same width only amounts to a few percent, and such loop elements can therefore be used for the same purpose, e.g. in car seats.
  • In practice, two or three loop elements, located one inside the other, can be formed at the same time, but in principle, even four or more-loop elements may be produced. Already in case of two complementary elements the material can be used up to about 70-80%, which means a considerable economic saving compared to conventional manufacturing methods. Moreover, the waste obtained when forming by punching is more favourable for re-use than by etching.
  • Thus, the loop elements located inside each other will be approximately equal in length. If so desired, the actual differences in length, which are small, may be compensated by making the shorter loop elements somewhat narrower so that the resistance becomes equal.
  • From the point of view of productivity, it is advantageous to punch a laminate consisting of the metal foil itself and two cover foils of thermoplastic material, e.g. polyester, on each side thereof, the two cover foils being stretched over the edges of the metal foil loop elements and being joined along these edges under the influence of heat, so that the metal foil loop elements are entirely closed by the cover foils. The joining can possible be effected during the punching operation by an adjusted design and heating of the punching tools.
  • Suitably, the punching is performed by means of stamp and die, but principally, even a cutting punch can be used. A possible alternative to the punching operation is conventional production by etching the loop elements located inside each other. In such a case, a metal foil is applied to a supporting layer, preferably of thermoplastic material, such as polyester, and after etching the complementary loop elements a cover layer may be applied. Thereafter, the loop elements are punched out together with the metal foil loops enclosed between the enclosing layers.
  • The invention will be described further below with reference to the appended drawing, which illustrates a simple embodiment.
    • Fig. 1 shows in a planar view two foil loops, one inside the other, which have been punched out from a unitary foil laminate; and
    • Figs. 2 and 3 show each of the two loop. elements separately.
  • The embodiment illustrated in Fig. 1 consists of two foil loop elements 1, 2 located one (element 1) closely inside the other(element 2) and having complementary meander loop portions, also shown in Figs. 2 and 3, illustrating the configuration of each loop element 1, 2. As is known from SE-A-7713250-4 and SE-A-8205712-6 the different loop portions extend in different main directions, i.e. substantially perpendicular to each other.
  • With such an arrangement, it has turned out that the difference in resistance between the elements 1, 2 in Figs. 2 and 3 is only about 2%.
  • In the example the metal foil is made of a rustproof plate material having a thickness of about 35 pm. The metal foil is enclosed at both sides by polyester plastic which is punched simultaneously in one operation by means of a punch tool formed in correspondence to the configuration shown in Fig. 1.
  • In general, the metal foil may have a thickness of 20-100pm. If three loop elements are punched out at the same time, the thickness should be larger than the thickness of only two coil members, e.g. about 50 um.
  • In the embodiment the punched out loop elements are short circuited by a metal connection C1 (Fig. 2) and C2 (Fig.3), respectively. The purpose of this connection is to make the element stable enough during the assembly of the connection cables and an outer casing, e.g. in the form of a plastic net. Thereafter, the connection is cut away. As an alternative to such metal connections, one of the plastic foils, e.g. the lower one, may have larger dimensions than the metal foil and the other plastic foil, so that a protruding plastic foil portion (not to be punched) constitutes the desired connection, which provides the member with the necessary stability during assembly.
  • Of course, the form of the loop may vary at wish in view of the intended use. Thus, the meander loops may extend in mutually oblique main directions or in only one main direction. The loop elements do not necessarily have to be meander-shaped, but may have any, preferably closed configuration. The essential feature is that the loop elements are situated complementarily one inside the other and together cover the major part of the surface area in question so as to reduce the waste of material.

Claims (4)

1. A method of manufacturing loop-formed metal foil elements intended to serve as electrical resistance heating elements, characterized by simultaneously forming by punching at least two meander-like, substantially closed loop elements (1, 2) from a unitary foil laminate including a metal foil, said loop elements extending closely and complementarily inside one another and jointly covering at least 70% of the surface area confined within the outer contour of the outer of the at least two elements, each such loop element (1, 2) having substantially the same electrical resistance and mutually adjacent parts thereof well separated from each other, whereby the simultaneously formed loop elements can be used individually for the same purpose.
2. A method as defined in claim 1, characterized in that the loop elements (1, 2) are punched into such a closed meander-like configuration that they are approximately equal in length and have a difference in resistance not exceeding 2%.
3. A method according to claim 1 or 2, characterized in that said loop elements are formed by punching from a laminate consisting of said metal foil and two cover foils of thermoplastic material arranged on both sides thereof, wherein the two cover foils are stretched over the edges of said metal foil loop elements and are joined along said edges under the influence of heat, so that said metal foil loop elements are entirely enclosed all around by said cover foils.
4. A method according to claim 2, characterized in that said joining under the influence of heat is effected during the punching operation.
EP85850249A 1984-08-24 1985-07-26 Method of manufacturing loop-formed metal foil elements Expired - Lifetime EP0175662B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE8404231 1984-08-24
SE8404231A SE8404231L (en) 1984-08-24 1984-08-24 SET TO MAKE SLEEPING METAL FILM ELEMENTS

Publications (2)

Publication Number Publication Date
EP0175662A1 EP0175662A1 (en) 1986-03-26
EP0175662B1 true EP0175662B1 (en) 1990-07-11

Family

ID=20356794

Family Applications (1)

Application Number Title Priority Date Filing Date
EP85850249A Expired - Lifetime EP0175662B1 (en) 1984-08-24 1985-07-26 Method of manufacturing loop-formed metal foil elements

Country Status (6)

Country Link
US (1) US4642887A (en)
EP (1) EP0175662B1 (en)
JP (1) JPS61108429A (en)
DE (1) DE3578627D1 (en)
ES (1) ES8705180A1 (en)
SE (1) SE8404231L (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19638640A1 (en) * 1996-09-21 1998-04-02 Ako Werke Gmbh & Co Radiant heater with a metal foil heating conductor

Families Citing this family (11)

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Publication number Priority date Publication date Assignee Title
SE8505911L (en) * 1985-12-13 1987-06-14 Kanthal Ab Foil elements
FR2678466B1 (en) * 1991-06-27 1993-09-03 Navarra Componentes Electronic HEATING DEVICE BY CONTACT THERMAL TRANSFER.
DE19524943C2 (en) * 1995-07-08 2003-05-08 Siemens Ag sensor
US5783743A (en) * 1995-07-08 1998-07-21 Vdo Adolf Schindling Ag Moisture sensor
DE10126134B4 (en) * 2001-05-29 2004-02-26 W.E.T. Automotive Systems Ag Flat heating element
WO2004002806A1 (en) * 2002-06-28 2004-01-08 W.E.T. Automotive Systems Ag Steering wheel with electrical heating element
JP5753577B2 (en) * 2010-05-27 2015-07-22 ダブリユーイーテイー・オートモーテイブ・システムズ・リミテツド Heater for motor vehicle and method of forming the same
EP2845764B1 (en) 2013-09-05 2017-05-24 ALT Technologies B.V. Flexible laminate
CN108712790B (en) * 2018-04-08 2021-04-06 佛山市瑞福物联科技有限公司 Circuit arrangement method
LU101364B1 (en) * 2019-08-22 2021-03-05 Iee Sa Hybrid Printed Heater with Optional PTC Effect
CN113611468A (en) * 2021-07-26 2021-11-05 电子科技大学 Method for manufacturing resistive film and micro-area hot plate

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US1498969A (en) * 1920-01-03 1924-06-24 William H Keller Manufacture of resistance grids
US1606282A (en) * 1924-10-29 1926-11-09 Claude A Witter Process of making pipe flanges
GB912980A (en) * 1958-01-13 1962-12-12 Eisler Paul Production of laminates embodying electrically conductive patterns
US3495328A (en) * 1967-07-07 1970-02-17 Corning Glass Works Electric heating unit
FR2141562B1 (en) * 1971-06-16 1974-03-08 Cebal Gp
US4002883A (en) * 1975-07-23 1977-01-11 General Electric Company Glass-ceramic plate with multiple coil film heaters
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DE2615064A1 (en) * 1976-04-07 1977-10-20 Husqvarna Ab COOKING PAN WITH ELECTRONICALLY CONTROLLED TEMPERATURE REGULATION AND A PROCESS FOR MANUFACTURING THE SAME
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DE3068319D1 (en) * 1979-11-02 1984-07-26 Linton & Hirst Ltd Method for forming laminations for transformer cores
US4378489A (en) * 1981-05-18 1983-03-29 Honeywell Inc. Miniature thin film infrared calibration source
SE8205712L (en) * 1982-10-06 1984-04-07 Bulten Kanthal Ab HEATING DEVICE AND WAY TO MANUFACTURE THEM

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19638640A1 (en) * 1996-09-21 1998-04-02 Ako Werke Gmbh & Co Radiant heater with a metal foil heating conductor
DE19638640C2 (en) * 1996-09-21 2000-11-30 Diehl Ako Stiftung Gmbh & Co Radiant heater with a metal foil heating conductor

Also Published As

Publication number Publication date
SE8404231L (en) 1986-02-25
EP0175662A1 (en) 1986-03-26
SE8404231D0 (en) 1984-08-24
ES8705180A1 (en) 1987-04-16
ES546310A0 (en) 1987-04-16
DE3578627D1 (en) 1990-08-16
US4642887A (en) 1987-02-17
JPS61108429A (en) 1986-05-27

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